Optimization of Mining and Classification Processes through Linear Programming: Tanlahua Quarry Case, Ecuador
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Abstract
Open-pit mining operations in Ecuador face the constant challenge of reducing production costs without compromising required extraction volumes. At the Tanlahua quarry (San Antonio de Pichincha), operated by EXPLOCOM, inefficiencies were identified in the excavation, hauling, sorting, and dispatch processes, with significant downtime negatively impacting profitability. Objective. To optimize the mining and sorting processes at the Tanlahua mining area through the application of the Simplex Method of linear programming. Materials and methods. A descriptive, prospective, and field study focused on the concession’s operational processes. Techniques included direct observation, cycle time studies, hourly cost analysis, and machinery performance evaluation. Data were processed using JSimplexsoftware to solve objective functions aimed at minimizing operating costs. Results. In high-demand scenarios, the optimized model generated a daily saving of USD 1,068.15 (36.1% reduction), while in low-demand conditions, the saving reached USD 486.85 per day (35.5% reduction). Considering 312 working days, the estimated annual savings amount to USD 242,580. Conclusion. The application of the Simplex Method enables efficient machinery allocation and a reduction in operating costs exceeding 35%, serving as a highly relevant technical-economic management tool for stone aggregate quarries
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